Automatic stitching of footwear parts

ABSTRACT

A method and a system for manufacturing footwear. The footwear including at least two footwear parts. The footwear parts are at least partly connected together by stitching for forming at least part of an upper part of the footwear. The method includes providing a base layer and providing the at least two footwear parts. The at least two footwear parts are positioned on the base layer. The at least two footwear parts are fixated on the base layer in respective relative positions corresponding to predefined connected positions. The at least two footwear parts are connected with each other by an automated stitching. The at least two footwear parts in connected form to provide the footwear.

The invention relates to a method of manufacturing footwear, saidfootwear comprising at least two footwear parts, e.g. shoe parts, whichfootwear parts are at least partly connected together by stitching forforming at least part of an upper part of said footwear.

The invention furthermore relates to a system for manufacturingfootwear, said footwear comprising at least two footwear parts, e.g.shoe parts, which footwear parts are at least partly connected togetherby stitching for forming at least part of an upper part of saidfootwear.

BACKGROUND OF THE INVENTION

Prior art methods and systems for manufacturing footwear rely to a largedegree on manual handling of e.g. footwear parts, including manualhandling of footwear parts when these are positioned prior to beingconnected by stitching and including manual operation in connection withstitching, etc. In the prior art, custom made jigs have been used, e.g.for fixating footwear parts after they have been manually positioned.However, such prior art systems require a multitude of variouscustom-made jigs to be made and to be made available at themanufacturing facility, which may increase manufacturing costs. Also, itis noted that such methods are still relatively labour intensive. Thus,it is desired to reduce the rate of manual labour in connection withmanufacture of footwear.

SUMMARY OF THE INVENTION

The invention relates to a method of manufacturing footwear, saidfootwear comprising at least two footwear parts, e.g. shoe parts, whichfootwear parts are at least partly connected together by stitching forforming at least part of an upper part of said footwear, said methodcomprising

-   -   providing a base layer,    -   providing said at least two footwear parts and positioning said        at least two footwear parts on said base layer,    -   fixating said at least two footwear parts on said base layer in        respective relative positions corresponding to predefined        connected positions,    -   connecting said at least two footwear parts with each other by        an automated stitching, and    -   further processing the at least two footwear parts in connected        form to provide said footwear.

Hereby, the manufacturing of footwear may be improved as regardscost-efficiency and production speed, for example since themanufacturing may take place in a highly or at least partly automatedmanner and since the base layer may serve as a means of accommodatingthe footwear parts in individual form as well as in the processedconnected form after being stitched. Thus, the base layer may also serveas a means for handling the footwear parts, the connected footwear partsand/or other assemblies of footwear parts and may serve as a means fortransport, e.g. along a process line, from one processing step to thenext, etc. Thus, manual handling may be reduced or possibly totallyavoided for a large number of process steps, e.g. since the base layerwith or without the positioned and/or processed parts may be serve as awork base as well as transport means.

According to an embodiment, the base layer may be a uniform sheet orlayer of material, e.g. wherein the base layer may be continuous alongat least a part of the length and a least a part of the width of thebase layer and having essentially uniform characteristics.

According to an embodiment, the base layer may be a uniform sheet orlayer of material, e.g. wherein the base layer may be continuous alongthe length and the width of the base layer and having essentiallyuniform characteristics.

According to advantageous embodiments, the at least two footwear partsthat are being fixated and later e.g. stitched together and/or to thebase layer may for example be

a toe cap and a vamp,a vamp and a tongue,a vamp and a quarter,a quarter and an outer counter,a facing and a quarter.

Thus, the method according to these embodiments may involve that anysuch combination of footwear parts is provided and positioned on thebase layer in accordance with the invention. It will be understood thatthe order, in which the at least two footwear parts are provided andpositioned may be arbitrary but may customarily depend on the actualfootwear construction and/or design. Thus, in case the specificcombination of footwear parts is a vamp and a tongue, the vamp may bepositioned as the first out of the at least two and the tongue as thesecond footwear part, but the order of positioning these two footwearparts may be reversed.

Furthermore, it will be understood that other combinations than theabove-mentioned may be selected as the at least two footwear parts to beprovided and positioned, etc. in accordance with specific embodiments ofthe invention.

Even further, it is noted that the at least two footwear parts may bepositioned and subsequently fixated on the base layer with the side ofeach of the at least two footwear parts that normally will be facing theinner of the completed footwear facing the base layer. Other variationsare possible, e.g. with one of the at least two footwear parts beingreversed.

According to the invention, advantages may be achieved due toautomation, e.g. as regards cost-efficiency, production speed, etc. asmentioned above. In particular, the automation may be effected due tothe automated stitching, which may be provided by an automated stitchingdevice, e.g. a motor driven stitching device, which furthermore mayperform the stitching in an at least partly automatically controlledmanner, which may be applied in a multitude of ways. For example, thestitching device may perform the stitching in accordance with apredefined route, defined in relation to the positions and/ororientation of the at least two footwear parts that have been fixated onthe base layer. Thus, a stitching route or routes may be defined in e.g.an X-Y system on the base layer and implemented by the stitching device.Another possibility is that the automated stitching device is configuredto stitch along a route, which has been indicated on at least one of theat least two footwear parts, e.g. with a visible marking, which may befollowed by the stitching device, which may receive input data from ane.g. vision device, which may be combined with the stitching device ormay be an independent device. Such a marking may instead be invisible,e.g. an electronical or magnetic trail, a radiation trail, etc. whichmay require corresponding sensing devices to control the stitchingdevice. Also, it may be a possibility that the stitching device may becontrolled to follow an edge of one of the at least two footwear partsand stitch in a predetermined distance to the relevant footwear part, inwhich case input data may be provided by vision equipment or other meansof detecting and/or following e.g. an edge part. Other options forcontrolling or guiding the automated stitching are possible. Also, itmay be a possibility that such options may be combined, for example incase a stitching route is defined as a route in relation to an X-Ysystem on the base layer, where furthermore it may be supplemented witha guiding system, for example using a vision system to effect apredefined distance to an edge of one of the footwear parts and/or whichensures that the stitching is started and/or stopped, when e.g. the atleast two footwear parts are not overlapping.

According to advantageous embodiments, the method may be automated inother manners. For example, the base layer may be provided in anautomated manner, for example being delivered by a denesting device or asimilar arrangement, whereby the base layers from e.g. a stack are beingdelivered one by one and for example put onto a conveyor system or thelike. Robotic delivering means may also be utilized for providing thebase layers.

As regards the step of providing the at least two footwear parts andpositioning these various manners of automating these may be utilized,including the use of robotic means, e.g. robots that may grip thefootwear parts by e.g. vacuum grippers and place these on the baselayer, controlled by a controller that further receives input as regardsthe position of the footwear part e.g. above the base layer. In thisconnection it is noted that in case robotic vacuum grippers are used,these may be equipped with a plurality of relatively small suctions cupsor the like, e.g. arranged in an array corresponding to e.g. the size offootwear parts to be gripped. The individual suction cups or the likemay be individually supplied with vacuum. Additionally, it is noted thata further axis of the vacuum gripper robot may be implemented by havingthe active suctions cups or the like, e.g. the suction cups actuallygripping a footwear part, be controlled to be extended or in anotherconfiguration by having the inactive suction cups be controlled to beretracted, when gripping, positioning and/or moving etc. a footwearpart. Hereby, a number of advantages may be achieved, e.g. that theinactive suctions cups or the like that are actually not involved ingripping a footwear part, will not be near or will at least bepositioned a distance from the footwear part, thus making it easier tomaneuver the vacuum gripper and/or the gripped footwear part, e.g.because the inactive suctions cups or the like are less likely tocollide with other objects, for example a fixture for the base layer,conveyor parts or other parts involved in the processing. Hence, therobotic vacuum gripper may, when implemented in such a manner with afurther axis, be used with greater delicacy, with greater precision andin general with greater degrees of freedom as regards e.g. the abilityto turn or in general angularly maneuver a footwear part, position afootwear part near a frame or fixture for the base layer, utilize theavailable base layer area to a greater extent, etc. Other automationmeans are possible in this regard.

Further, as regards the fixating of the at least two footwear parts onthe base layer, various manners of automating this will be available asit has been exemplified herein. Thus, automation may be implemented inconnection with application of adhesives, e.g. automated application incertain areas, etc., activation of applied adhesives, etc., whereautomated devices may be utilized.

Even further, it should be noted that in connection with the furtherprocessing of the at least two footwear parts in connected form toprovide a completed piece of footwear numerous automation steps andautomation means may be presented as it has been exemplified in thepresent application.

According to an embodiment of the invention, at least one of said atleast two footwear parts may be a leather footwear part.

In an embodiment of the invention, the method may further comprise thestep of providing a fixture for said base layer and may comprise thestep of arranging the base layer to be held by said fixture.

Hereby, the base layer, when held by such a fixture, may provideimproved characteristics as regards e.g. strength, rigidity, loadbearing capability, precision as regards positioning of e.g. footwearparts on it, etc. since the fixture may serve as a rigid frame or thelike, by means of which the base layer may be e.g. tightened, forexample to provide a planar surface, on which the e.g. footwear partsmay be positioned with great precision. Furthermore, the fixture mayfacilitate the e.g. handling and/or transport of the base layer, with orwithout parts positioned on it.

In an embodiment of the invention a reference may be provided forpositioning said at least two footwear parts on said base layer.

Hereby, the positioning of the at least two footwear parts is supported,for example in case the position and/or orientation of the at least twofootwear parts is based on distances from the reference, coordinatesbased on a reference coordinate system, etc. The reference may be avisual reference, which may be utilized when manually positioning the atleast two footwear parts and/or which may also be utilized whenpositioning the at least two footwear parts in an automated manner, e.g.using a robotic unit that may have vision means to enable the placing.The reference may instead be based on other means such as electronicmeans, magnetic means, radiation means of various kinds, etc, as it willbe apparent to a person skilled within the art of automation and relatedfields.

According to an embodiment of the invention, said reference may beprovided by the base layer and/or said fixture for the base layer.

Hereby, the reference may be provided in advantageous manners, e.g.combined and/or incorporated with the base layer, e.g. embedded in orplaced on the base layer material for example as a visual coordinatesystem or as an electronic device indicating origin and direction to beused by e.g. a robot. Similar applies when the reference is provided bythe fixture, but where e.g. a rectangular frame may serve to provide thereference, for example with one inner corner providing the origin andthe corresponding two frame parts providing x- and y-axes that may bedetected using visual means or other means, e.g. in case one or moredetectable objects have been embedded in the frame, which for examplemay be made from epoxy or other synthetic materials, e.g. glass fibrereinforced epoxy or similar materials. Further, it is noted that sincethe fixture preferably is reusable, a reference provided by the fixturemay be technically more advanced, which relates to the reference meansitself as well as the detector or sensing means that for exampleprovides control input to e.g. a robotic apparatus for placing theparts.

According to an embodiment of the invention, said step of fixating saidat least two footwear parts on said base layer in respective positionsmay comprise adhering the at least two shoe parts on said base layerwith an adhesive.

Hereby, it may be achieved that the at least two footwear parts may notbe accidentally moved from the intended position(s) and may remain thereuntil having been connected by the automated stitching. Such unintendedmoving of the at least two footwear parts might otherwise happen whenthe base layer or the fixture is being transported from one process stepto the next and in particular when the base layer and the at least twofootwear parts has to the stitched by an automatic stitching apparatus.

According to an embodiment of the invention, said adhesive may beprovided as a non-activated adhesive on said base layer, which isactivated when fixating the at least two footwear parts on the baselayer.

Hereby, it is achieved that the at least two footwear parts may beadhered to the base layer in a relatively uncomplicated manner, when thefootwear parts have been positioned, at which point in time the adheringmay be established by activating the adhesive, which may be done invarious manners. It is noted that in case one of the two at least twofootwear parts is overlapping the other and it is intended to fixatethese two at e.g. the overlap as well, the overlap part of at least oneof the at least two footwear parts may have been applied with adhesivein advance or in connection with the positioning of the footwear parts.When the non-activated adhesive of the base layer is activated, theadhesive of the overlap part(s) may be activated at the same time.

In an embodiment of the invention, said non-activated adhesive on saidbase layer may be activated using friction, pressure, ultrasonicradiation, infrared radiation, heat transfer or any combination hereof.

Heat transfer may be applied by heat conducting or heat conduction.

The non-activated adhesive is defined as an adhesive that has not yetbeen activated.

Adhesives may be non-reactive glue e.g. hot-melt adhesives includingthermo-polymer, polyamide, polyesters, polyurethane, polyolefins etc.

Hot melt glues may consist of one base material with various additives.The composition is usually formulated to have a glass transitiontemperature (onset of brittleness) and a suitable high melt temperatureas well.

The hot-melt adhesive may have a Tg (Tg: Glass transition temperature)between 50 degrees Celsius and 200 degrees Celsius, such as between 100degrees Celsius and 200 degrees Celsius, such as between 110 degreesCelsius and 200 degrees Celsius, such as between 120 degrees Celsius and200 degrees Celsius, such as between 100 degrees Celsius and 180 degreesCelsius, such as between 100 degrees Celsius and 170 degrees Celsius.

An advantage of applying heat to the process is that it is possible tocontrol the adherence of adhesive to leather. The temperature is raisedas the adhesive is applied to the leather and/or base layer as e.g. aweb and needs to be heated in order to melt and facilitate a strongmutual bonding between the leather pieces/layers.

The pressure P applied may be at least 2 bar, such as at least 3 bar,such as at least 4 bar, such as at least 5 bars. Pressure should bebelow a pressure where the leather is damaged or where the bonding isnot performed according to intentions. An upper pressure could e.g. be15 bar.

An advantage of applying pressure to the leather during heating of theleather is that the temperature of the leather may be lower than if notapplying pressure. The lower temperature is an advantage as the leathermay not be burned and it will further keep the leather in the rightshape with a minimum of shrinkage. If the temperature is too high, theleather may lose its moisture and therefore turn hard and wavy andthereby loose the flexibility and softness of the leather.

According to an embodiment of the invention, leather layers comprisingsaid non-activated adhesive may have a water vapor permeability of above5 mg/cm2/hour, such as above 8 mg/cm2/hour, such as above 10mg/cm2/hour.

Hereby, the material allows liquid water (perspiration) to transportaway from the skin to the outside, thus allowing comprehensive comfortto the wearer. Breathability and water vapor permeability may be usedinterchangeably and may be evaluated by suitable methods for determiningwater vapor permeability of leather. Standard methods such as SATRA™ 172may be used to test the water vapor permeability. Briefly, themeasurement may be of a test piece of material fixed over the opening ofajar. Mass of the moisture passing through the test piece in the jar isweighted and water vapor permeability can be calculated.

According to an embodiment of the invention, the positioning of said atleast two footwear parts on said base layer may be performed by arobotic pick and place apparatus, e.g. by sequentially picking each shoepart and placing it on the base layer at a predefined position andpossibly with a predefined orientation.

Hereby, it is achieved that when an empty base layer has been provided,possibly held by a fixture, the robotic pick and place apparatus may,controlled by control software of an e.g. central or local control unit,pick a first one of the at least two footwear parts from e.g. a localstore and place it on the base layer, possibly at a predeterminedposition and possibly with a predetermined orientation. Subsequently,the robotic pick and place apparatus may, controlled by the controlsoftware, pick a second one of the at least two footwear parts from e.g.a local store and place it on the base layer, possibly at apredetermined position and/or with predetermined orientation or possiblyat a predetermined position and/or with a predetermined orientation inrelation to the first footwear part. In case more than two footwearparts have to be placed, these steps may be repeated.

It is noted that the footwear parts may be supplied to the robotic pickand place apparatus in the order, in which they have to be placed andthat they in this manner are being identified to the robotic pick andplace apparatus. It is also a possibility that the individual types offootwear parts are stored in individual e.g. store compartments, knownto the control system and that the robotic pick and place apparatus inthis manner may be controlled to pick the right footwear parts in theright order. A still other possibility is that the individual types offootwear parts are provided with identifications, e.g. numbers, barcodes, RFID devices, etc. that are readable by the robotic pick andplace apparatus and that the robotic pick and place apparatus in thismanner identifies the correct footwear part to be picked, e.g. thecorrect type, the right size, the right colour, left or right type, etc.

According to an embodiment of the invention, the at least two footwearparts may be stacked on the base layer and/or a plurality of said baselayers may be stacked.

Hereby, improvements may be achieved as regards efficiency. For example,it is noted that empty fixture frames may advantageously be stacked,whereby the job of mounting a base layer in each of these may befacilitated, and that the such prepared fixture frames may also bestacked, ready to be added to e.g. an input of the manufacturing line.In a similar manner, the fixture frames that have travelled through theprocessing may be stacked, e.g. after being relieved of surplus baselayer material, etc. and be made ready to be re-introduced in themanufacturing liner.

According to an embodiment of the invention, the positioning of said atleast two footwear parts on said base layer may be performed using inputfrom a visual detection system, e.g. using a camera, a vision system orthe like.

Hereby, it is achieved that the positioning of the first as well as thesubsequent footwear parts may be placed optimally as well asefficiently, e.g. using not only a possible reference and/or a fixtureframe as reference, when placing the first footwear part, but also usingan already placed footwear part, when placing a subsequent footwearpart, so that e.g. a possible overlap between the parts will have anoptimal size in view of e.g. a stitching seam or the like and wherebythe finished product may have the required characteristics as regardse.g. strength as well as appearance.

According to an embodiment of the invention, said automated stitchingmay be made by an automated stitching device.

Hereby, it is achieved that the connection of the footwear parts may bemade relatively quickly, efficiently and with the required precision,which in the prior art has not been possible, since an automatedstitching of footwear parts, e.g. leather footwear parts has proven tobe difficult to exercise and has turned out to have certaindeficiencies, such as lack of precision, ill-fitting parts, etc.However, in connection with the invention, where a base layer is usedand where the at least two footwear parts are fixated to this baselayer, it has been shown that an automated stitching using an automatedstitching device may be performed due to the footwear parts beingfixated in the intended positions and whereby the desired quality andappearance of the completed footwear may be achieved.

It is noted that in connection with the automated stitching of the atleast two footwear parts, of which at least one of these and possiblyboth may be a leather footwear part, the respective footwear parts maybe positioned and fixated on the base layer such that considerations aremade as regards possible shifting of the overlapping leather parts thatmay happen, when stitching, due to the thickness and inherentcharacteristics such as flexibility of the leather material. Thus, whendetermining, e.g. by control software and by a control system, therespective positions for the at least two footwear parts, adjustmentsmay be made to anticipate any movements of the leather parts that mayhappen during the automated stitching, such that the finished result maycome out as originally intended. In the prior art, such stitching isusually made manually by experienced persons, who during the machinestitching may make e.g. small adjustments and corrections to achieve asatisfactory result in spite of the movements of the leather material.According to this embodiment of the invention, initial adjustments maybe made to anticipate such movements, whereby an automated stitching maybe made of the at least two footwear parts that are fixated to the baselayer.

It should be noted that an automated stitching device in this connectionwill be understood as being an e.g. motor driven stitching device, whichfurthermore may perform the stitching in an at least partlyautomatically controlled manner. The at least partly automatic controlmay be applied in a multitude of ways. For example, the stitching devicemay perform the stitching in accordance with a predefined route, definedin relation to the positions and/or orientation of the at least twofootwear parts that have been fixated on the base layer. Thus, astitching route or routes may be defined in e.g. an X-Y system on thebase layer and implemented by the stitching device. Another possibilityis that the automated stitching device is configured to stitch along aroute, which has been indicated on at least one of the at least twofootwear parts, e.g. with a visible marking, which may be followed bythe stitching device, which may receive input data from an e.g. visiondevice, which may be combined with the stitching device or may be anindependent device. Such a marking may instead be invisible, e.g. anelectronical or magnetic trail, a radiation trail, etc. which mayrequire corresponding sensing devices to control the stitching device.Also, it may be a possibility that the stitching device may becontrolled to follow an edge of one of the at least two footwear partsand stitch in a predetermined distance to the relevant footwear part, inwhich case input data may be provided by vision equipment or other meansof detecting and/or following e.g. an edge part. Other options forcontrolling or guiding the automated stitching are possible. Also, itmay be a possibility that such options may be combined, for example incase a stitching route is defined as a route in relation to an X-Ysystem on the base layer, where furthermore it may be supplemented witha guiding system, for example using a vision system to effect apredefined distance to an edge of one of the footwear parts and/or whichensures that the stitching is started and/or stopped, when e.g. the atleast two footwear parts are not overlapping.

According to an embodiment of the invention, said at least two footwearparts may subsequent to being positioned on said base layer betransportable by moving said base layer.

Hereby, the at least two shoe parts, when they are fixated, connected bystitching or even when they are not connected or fixated may be movedwith precision and efficiently when the base layer is moved, no matterwhether this is via a conveyor, via a robotic pick and place device orin any other suitable manner, including manual handling, for example inconnection with manual workstations, where for example the base layerand the connected at least two footwear parts may be processed manually,e.g. in connection with 3D stitching, transfer to a last, correctivehandling, inspection or the like. To this can be added the possibilityof handling the base layer with the at least two footwear partsconnected to the base layer for further process step. Here, it may benoted that in the first of a plurality of process steps the processesmay be performed in a single plane, i.e. a 2D plane, for examplestitching in a single plane as defined by the base layer held by afixture and/or the base layer held in itself by an e.g. conveyor.Subsequent to being removed from e.g. the fixture, the base layer withthe at least two footwear parts connected to the base layer may behandled and processed within a 3D space, where for example 3D stitchingof the footwear parts may be performed to provide a spatial form of thefootwear parts on the process path to provide a completed footwear.Furthermore, the base layer may be moved to a last for some of the laterprocess steps, in particular for the steps relating to the applicationof a sole, for direct injection moulding of a sole, etc.

According to an embodiment of the invention, said base layer may betransportable by moving said fixture, which may comprise conveyancearrangement.

Hereby, the at least two shoe parts carried by the base layer, no matterwhether they are fixated, connected by stitching or even when they arenot connected or fixated may be moved in an automated manner by movingthe fixture, which via the conveyance arrangement may be connected to aconveyor arrangement. The conveyor arrangement may be a traditionalconveyor belt, conveyor chain or the like, or may be a conveyor track orthe like, upon which the fixture may be transported and/or guided. Otherconveyor arrangements are possible.

Further, it is noted that the conveyance arrangement may be configuredin such a manner that the fixture and thus also the base layer may bemovable in relation to e.g. a conveyor, track or the like. Such amovement may be controllable by e.g. a control system and perform in anautomated manner, e.g. in order to place the fixture in a suitableposition, orientation, inclination, etc. for the actual processing stepto be performed, e.g. for example when allowing a heat press to fixatethe footwear parts by activating the adhesive and thus e.g. pressingfrom above as well as below. Another example may be tilting the fixturewhen allowing an automated stitching apparatus to grip on upper andlower side of the base layer to perform the stitching, etc. Thus, theconveyance arrangement may be configured to have several degrees orfreedom, e.g. being able to rotate around vertical as well as horizontalaxes, tilt sideways and/or lengthways, etc.

According to an embodiment of the invention, an identifier may beprovided for identifying at least one of the base layer, the fixture andat least one of the at least two footwear parts.

Hereby, the identity of the actual piece of footwear being manufacturedmay be known, e.g. whether it is the fixture, the base layer or at leastone of the footwear parts that are proceeding along the manufacturingline that is identified. Thus, when proceeding along the manufacturingline and through the processing steps, the control system may read theidentity and perform the correct next step to be performed. Thus, it mayfor example be possible that the control system, when identifying theactual fixture, the actual base layer and/or an actual footwear part,may know that it is left hand shoe being made in size 39 with a specificcolour and that the next step is addition of a facing. The controlsystem may thus retrieve such a shoe part and place it in the correctposition, where after the fixture may be conveyed further on forfixation of the facing and subsequent automated stitching of the facingto the assembly. Hence, it will be understood that due to theidentifier, the actual footwear being made may be understood aseffectively controlling the manufacturing and processing steps, e.g.being the actual controller itself, in that the specific steps beingperformed will depend on the actual identity of the footwear beingmanufactured.

According to an embodiment, such identifiers may be RFID devices orsimilar electronic devices.

According to an embodiment of the invention, the automated stitching mayinclude stitching at least part of one of said at least two footwearparts to the base layer.

Hereby, the automated stitching may be effected in a straightforwardmanner, e.g. by stitching through e.g. the at least two footwear partsas well as the underlying base layer. Further, it is achieved that partsof the base layer that in this manner is being stitched to the footwearparts that at least partly forms a footwear upper, may serve as a partof the completed piece of footwear.

According to an embodiment of the invention, the method may compriseremoval of the base layer from the at least two footwear parts prior tocompletion of the footwear or trimming of the base layer prior tocompletion of the footwear.

Hereby, the at least two footwear parts, when having been connected byautomated stitching and possibly after having been connected withfurther footwear parts, may be removed from the base layer and/orfixture at a suitable point in time, for example when stitching in asingle plane, i.e. 2D stitching has been made and subsequent stitchingin 3D is the next processing step and/or where the connected footwearparts are planned to be mounted on e.g. a last for the furtherprocessing steps. At these points in time, the base layer may possiblybe removed totally or only parts of the base layer that may not beneeded for the further processing and possible use in the completedfootwear may be removed, e.g. in connection with a trimming of thesurplus parts of the base layer and in connection with the removal of apossible fixture.

According to an embodiment of the invention, the base layer may be thelining of the footwear.

Hereby, the base layer may fulfil the function both as a based layer andas lining of the footwear. This will effectuate the process of shoemaking as the step of adding a lining may not be necessary. Lining isdefined as the material inside of the shoe that may come into contactwith the entire foot; sides, top and heels. The lining may be anysuitable material such as e.g. leather or fabric such as cotton andviscose and/or synthetic material like e.g. polyester, acrylic andelastane. Other material for cold weather shoes may also be used such ase.g. wool or lambskin.

According to an embodiment of the invention, there may be a furtherlayer of lining e.g. as a middle layer between the base layer and thelayer of leather. An advantage of a middle layer could be improvedinsulation, rigidity, durability or other advantages suitable forfootwear.

According to an embodiment of the invention, the elongation at break ofthe base layer may be less than 10%.

Suitably, the elongation at break of the base layer material (i.e. theelongation of the fabric when stretched to its breaking point) is lessthan 5%, typically less than 4%, or even less than 3%.

A suitable test for measuring the elongation at break is ISO3376:2011.

According to an embodiment of the invention, the base layer may be areinforcing fabric with a tensile strength (breaking strength) above 5N/mm, more typically above 10 N/mm, or even above 15 N/mm.

The ultimate tensile strength expressed in N/mm is the pulling forcerequired to break a 1 m wide sample of the material. A suitable test formeasuring the ultimate tensile strength of the reinforcing fabric is ISO3376: 2011.

According to an embodiment of the invention, the needle for stitching isat least 0.9 mm in diameter.

Hereby, the needle is thick enough to pierce the leather withoutbreaking the needle. Further, the needle may be spear shaped to help cutthe leather as the stitch is being formed.

Examples of needles suitable for sewing leather may be needles such ase.g. 110 LR, 110 FFG/R, 90 LR, 90 FFG/R.

According to an embodiment of the invention, the needle may comprise acoating.

Hereby, by using needles with a coating, it is possible to reducethermal and mechanical faults caused by the sewing needle. Duringsewing, the fabric resists the penetration of the needle. Thisfrictional resistance between the needle and the fabric produces heatand it may cause the needle to overheat during high-speed sewing.

Sewing needles may be coated with different materials such as e.g. Cr(Chrome), PTFE (Polytetrafluoroethylene) and TiN (Titanium nitride).

In an advantageous embodiment of the invention, the type of thread usedfor sewing may for example be synthetic sewing threads, e.g. made from amaterial such as e.g. polyester or nylon threads.

Examples of threads used for sewing, according to embodiments of theinvention, may be Amann Size 60/3, 40/3 and 20/3.

According to an embodiment of the invention, the stitching length may bemore than 3 stiches per cm, such as 3.5 stiches per cm, such as 4stiches per cm.

According to an embodiment of the invention, the method may furthercomprise inspection of said at least two footwear parts when said atleast two footwear parts have been positioned on the base layer, whensaid at least two footwear parts have been fixated and/or when said atleast two footwear parts have been connected by an automated stitching.

Hereby, it may be controlled that the respective manufacturing stepshave been performed as intended, before proceeding to the next steps,and in case it turns out that non-acceptable tolerances are detected,corrective actions may be taken and/or the relevant inspected item maybe removed from the processing for correction and/or re-use. Theinspection may be made by means of vision means, camera means, radiationmeans, etc.

In a further aspect, the invention relates to a system for manufacturingfootwear, said footwear comprising at least two footwear parts, e.g.shoe parts, which footwear parts are at least partly connected togetherby stitching for forming at least part of an upper part of saidfootwear, said system comprising

-   -   a base layer holding device configured for holding a base layer,    -   a positioning device for positioning at least two footwear parts        on said base layer,    -   an adhering activating device configured for fixating said at        least two footwear parts on said base layer in respective        relative positions,    -   an automated stitching device configured for connecting said at        least two footwear parts with each other, and    -   at least a further processing device for facilitating further        processing of the at least two footwear parts in connected form        to provide said footwear.

In an embodiment of the invention, at least one of said at least twofootwear parts may be a leather footwear part.

In an embodiment of the invention, said base layer holding deviceconfigured for holding said base layer may be a fixture.

Hereby, the base layer, when held by such a fixture, may provideimproved characteristics as regards e.g. strength, rigidity, loadbearing capability, precision as regards positioning of e.g. footwearparts on it, etc. since the fixture may serve as a rigid frame or thelike, by means of which the base layer may be e.g. tightened, forexample to provide a planar surface, on which the e.g. footwear partsmay be positioned with great precision. Furthermore, the fixture mayfacilitate the e.g. handling and/or transport of the base layer, with orwithout parts positioned on it.

In an embodiment of the invention, said fixture may comprise conveyancearrangements configured for transport of said fixture.

In an embodiment of the invention, said positioning device may comprisea robotic apparatus, e.g. a robotic pick and place apparatus.

In an embodiment of the invention, said positioning device may furthercomprise a visual detection system, e.g. comprising a camera, a visionsystem, etc.

In an embodiment of the invention, said adhering activating device maybe configured for fixating said at least two footwear parts on said baselayer in respective relative positions comprising an arrangement foractivating non-activated adhesive, e.g. using friction, pressure,ultrasonic radiation, infrared radiation, heat transfer or anycombination hereof.

Hereby, it may be achieved that the at least two footwear parts may notbe accidentally moved from the intended position(s) and may remain thereuntil having been connected by the automated stitching. Such unintendedmoving of the at least two footwear parts might otherwise happen whenthe base layer or the fixture is being transported from one process stepto the next and in particular when the base layer and the at least twofootwear parts has to the stitched by an automatic stitching apparatus.

Hot melt glues may consist of one base material with various additives.The composition is usually formulated to have a glass transitiontemperature (onset of brittleness) and a suitable high melt temperatureas well.

The hot-melt adhesive may have a Tg (Tg: Glass transition temperature)between 50 degrees Celsius and 200 degrees Celsius, such as between 100degrees Celsius and 200 degrees Celsius, such as between 110 degreesCelsius and 200 degrees Celsius, such as between 120 degrees Celsius and200 degrees Celsius, such as between 100 degrees Celsius and 180 degreesCelsius, such as between 100 degrees Celsius and 170 degrees Celsius.

An advantage of applying heat to the process is that it is possible tocontrol the adherence of adhesive to leather. The temperature is raisedas the adhesive is applied to the leather and/or base layer as e.g. aweb and needs to be heated in order to melt and facilitate a strongmutual bonding between the leather pieces/layers.

The pressure P applied may be at least 2 bar, such as at least 3 bar,such as at least 4 bar. Pressure should be below a pressure where theleather is damaged or where the bonding is not performed according tointentions. An upper pressure could e.g. be 15 bar.

An advantage of applying pressure to the leather during heating of theleather is that the temperature of the leather may be lower than if notapplying pressure. The lower temperature is an advantage as the leathermay not be burned and it will further keep the leather in the rightshape with a minimum of shrinkage. If the temperature is too high, theleather may lose its moisture and therefore turn hard and wavy andthereby loose the flexibility and softness of the leather.

In an embodiment of the invention, said system may comprise a referencefor positioning said at least two footwear parts on said base layer.

Hereby, the positioning of the at least two footwear parts is supported,for example in case the position and/or orientation of the at least twofootwear parts is based on distances from the reference, coordinatesbased on a reference coordinate system, etc. The reference may be avisual reference, which may be utilized when manually positioning the atleast two footwear parts and/or which may also be utilized whenpositioning the at least two footwear parts in an automated manner, e.g.using a robotic unit that may have vision means to enable the placing.The reference may instead be based on other means such as electronicmeans, magnetic means, radiation means of various kinds, etc, as it willbe apparent to a person skilled within the art of automation and relatedfields.

In an embodiment of the invention, said base layer and/or said fixturefor the base layer may comprise said reference.

In an embodiment of the invention, said base layer may comprise anadhesive on at least a part of its surface.

Hereby, it may be achieved that the at least two footwear parts may notbe accidentally moved from the intended position(s) and may remain thereuntil having been connected by the automated stitching. Such unintendedmoving of the at least two footwear parts might otherwise happen whenthe base layer or the fixture is being transported from one process stepto the next and in particular when the base layer and the at least twofootwear parts has to the stitched by an automatic stitching apparatus.

In an embodiment of the invention, the system may further comprise anapplicator for applying adhesive to at least part of said base layerand/or at least part of at least one of said at least two footwearparts.

In an embodiment of the invention, said adhesive may be provided as anon-activated adhesive on said base layer and/or said at least one ofsaid at least two footwear parts, which non-activated adhesive isactivatable for fixating the at least two footwear parts on the baselayer.

In an embodiment of the invention, said non-activated adhesive on saidbase layer and/or said at least one of said at least two footwear partsmay be activatable using friction, pressure, ultrasonic radiation,infrared radiation, heat transfer or any combination hereof.

In an embodiment of the invention, leather layers of said at least oneof said at least two footwear parts comprising said non-activatedadhesive may have a water vapor permeability of above 5 mg/cm2/hour,such as above 8 mg/cm2/hour, such as above 10 mg/cm2/hour.

Hereby, the material allows liquid water (perspiration) to transportaway from the skin to the outside, thus allowing comprehensive comfortto the wearer.

In an embodiment of the invention, said positioning device forpositioning said at least two footwear parts on said base layer maycomprise a robotic pick and place apparatus, e.g. configured forsequentially picking each footwear part and placing it on the base layerat a predefined position and possibly with a predefined orientation.

Hereby, it is achieved that when an empty base layer has been provided,possibly held by a fixture, the robotic pick and place apparatus may,controlled by control software of an e.g. central or local control unit,pick a first one of the at least two footwear parts from e.g. a localstore and place it on the base layer, possibly at a predeterminedposition and possibly with a predetermined orientation. Subsequently,the robotic pick and place apparatus may, controlled by the controlsoftware, pick a second one of the at least two footwear parts from e.g.a local store and place it on the base layer, possibly at apredetermined position and/or with predetermined orientation or possiblyat a predetermined position and/or with a predetermined orientation inrelation to the first footwear part. In case more than two footwearparts have to be placed, these steps may be repeated.

It is noted that the footwear parts may be supplied to the robotic pickand place apparatus in the order, in which they have to be placed andthat they in this manner are being identified to the robotic pick andplace apparatus. It is also a possibility that the individual types offootwear parts are stored in individual e.g. store compartments, knownto the control system and that the robotic pick and place apparatus inthis manner may be controlled to pick the right footwear parts in theright order. A still other possibility is that the individual types offootwear parts are provided with identifications, e.g. numbers, barcodes, RFID devices, etc. that are readable by the robotic pick andplace apparatus and that the robotic pick and place apparatus in thismanner identifies the correct footwear part to be picked, e.g. thecorrect type, the right size, the right colour, left or right type, etc.

In an embodiment of the invention, said robotic pick and place apparatusmay comprise a vacuum gripper.

In this connection it is noted that when a robotic vacuum gripper isused, this may be equipped with a plurality of relatively small suctionscups or the like, e.g. arranged in an array corresponding to e.g. thesize of footwear parts to be gripped. The individual suction cups or thelike may be individually supplied with vacuum. Additionally, it is notedthat a further axis of the vacuum gripper robot may be implemented byhaving the active suctions cups or the like, e.g. the suction cupsactually gripping a footwear part, be controlled to be extended or inanother configuration by having the inactive suction cups be controlledto be retracted, when gripping, positioning and/or moving etc. afootwear part. Hereby, a number of advantages may be achieved, e.g. thatthe inactive suctions cups or the like that are actually not involved ingripping a footwear part, will not be near or will at least bepositioned a distance from the footwear part, thus making it easier tomaneuver the vacuum gripper and/or the gripped footwear part, e.g.because the inactive suctions cups or the like are less likely tocollide with other objects, for example a fixture for the base layer,conveyor parts or other parts involved in the processing. Hence, therobotic vacuum gripper may, when implemented in such a manner with afurther axis, be used with greater delicacy, with greater precision andin general with greater degrees of freedom as regards e.g. the abilityto turn or in general angularly maneuver a footwear part, position afootwear part near a frame or fixture for the base layer, utilize theavailable base layer area to a greater extent, etc.

In an embodiment of the invention, said system may be configured forstacking parts such as the at least two footwear parts on the baselayer, a plurality of said footwear parts and/or a plurality of saidbase layers.

In an embodiment of the invention, the system may comprise a visualdetection system, e.g. having a camera, a vision system or the like forproviding input for the positioning device.

Hereby, it is achieved that the positioning of the first as well as thesubsequent footwear parts may be placed optimally as well asefficiently, e.g. using not only a possible reference and/or a fixtureframe as reference, when placing the first footwear part, but also usingan already placed footwear part, when placing a subsequent footwearpart, so that e.g. a possible overlap between the parts will have anoptimal size in view of e.g. a stitching seam or the like and wherebythe finished product may have the required characteristics as regardse.g. strength as well as appearance.

In an embodiment of the invention, said automated stitching device maybe configured for stitching at least part of one of said at least twofootwear parts to the base layer and/or to the other one of said atleast two footwear parts in an at least partly automatically controlledmanner.

Hereby, it is achieved that the connection of the footwear parts may bemade relatively quickly, efficiently and with the required precision,which in the prior art has not been possible, since an automatedstitching of footwear parts, e.g. leather footwear parts has proven tobe difficult to exercise and has turned out to have certaindeficiencies, such as lack of precision, ill-fitting parts, etc.However, in connection with the invention, where a base layer is usedand where the at least two footwear parts are fixated to this baselayer, it has been shown that an automated stitching using an automatedstitching device may be performed due to the footwear parts beingfixated in the intended positions and whereby the desired quality andappearance of the completed footwear may be achieved.

It is noted that in connection with the automated stitching of the atleast two footwear parts, of which at least one of these and possiblyboth may be a leather footwear part, the respective footwear parts maybe positioned and fixated on the base layer such that considerations aremade as regards possible shifting of the overlapping leather parts thatmay happen, when stitching, due to the thickness and inherentcharacteristics such as flexibility of the leather material. Thus, whendetermining, e.g. by control software and by a control system, therespective positions for the at least two footwear parts, adjustmentsmay be made to anticipate any movements of the leather parts that mayhappen during the automated stitching, such that the finished result maycome out as originally intended. In the prior art, such stitching isusually made manually by experienced persons, who during the machinestitching may make e.g. small adjustments and corrections to achieve asatisfactory result in spite of the movements of the leather material.According to this embodiment of the invention, initial adjustments maybe made to anticipate such movements, whereby an automated stitching maybe made of the at least two footwear parts that are fixated to the baselayer.

It should be noted that an automated stitching device in this connectionwill be understood as being an e.g. motor driven stitching device, whichfurthermore may perform the stitching in an at least partlyautomatically controlled manner. The at least partly automatic controlmay be applied in a multitude of ways. For example, the stitching devicemay perform the stitching in accordance with a predefined route, definedin relation to the positions and/or orientation of the at least twofootwear parts that have been fixated on the base layer. Thus, astitching route or routes may be defined in e.g. an X-Y system on thebase layer and implemented by the stitching device. Another possibilityis that the automated stitching device is configured to stitch along aroute, which has been indicated on at least one of the at least twofootwear parts, e.g. with a visible marking, which may be followed bythe stitching device, which may receive input data from an e.g. visiondevice, which may be combined with the stitching device or may be anindependent device. Such a marking may instead be invisible, e.g. anelectronical or magnetic trail, a radiation trail, etc. which mayrequire corresponding sensing devices to control the stitching device.Also, it may be a possibility that the stitching device may becontrolled to follow an edge of one of the at least two footwear partsand stitch in a predetermined distance to the relevant footwear part, inwhich case input data may be provided by vision equipment or other meansof detecting and/or following e.g. an edge part. Other options forcontrolling or guiding the automated stitching are possible. Also, itmay be a possibility that such options may be combined, for example incase a stitching route is defined as a route in relation to an X-Ysystem on the base layer, where furthermore it may be supplemented witha guiding system, for example using a vision system to effect apredefined distance to an edge of one of the footwear parts and/or whichensures that the stitching is started and/or stopped, when e.g. the atleast two footwear parts are not overlapping.

In an embodiment of the invention, the system may further comprise aconveying device wherein said at least two footwear parts subsequent tobeing positioned on said base layer are transportable by moving saidbase layer.

Hereby, the at least two shoe parts, when they are fixated, connected bystitching or even when they are not connected or fixated may be movedwith precision and efficiently when the base layer is moved, no matterwhether this is via a conveyor, via a robotic pick and place device orin any other suitable manner, including manual handling, for example inconnection with manual workstations, where for example the base layerand the connected at least two footwear parts may be processed manually,e.g. in connection with 3D stitching, transfer to a last, correctivehandling, inspection or the like. To this can be added the possibilityof handling the base layer with the at least two footwear partsconnected to the base layer for further process step. Here, it may benoted that in the first of a plurality of process steps the processesmay be performed in a single plane, i.e. a 2D plane, for examplestitching in a single plane as defined by the base layer held by afixture and/or the base layer held in itself by an e.g. conveyor.Subsequent to being removed from e.g. the fixture, the base layer withthe at least two footwear parts connected to the base layer may behandled and processed within a 3D space, where for example 3D stitchingof the footwear parts may be performed to provide a spatial form of thefootwear parts on the process path to provide a completed footwear.Furthermore, the base layer may be moved to a last for some of the laterprocess steps, in particular for the steps relating to the applicationof a sole, for direct injection moulding of a sole, etc.

In an embodiment of the invention, said fixture may comprise aconveyance arrangement.

Hereby, the at least two shoe parts carried by the base layer may bemoved in an automated manner by moving the fixture, which via theconveyance arrangement may be connected to a conveyor arrangement. Theconveyor arrangement may be a traditional conveyor belt, conveyor chainor the like, or may be a conveyor track or the like, upon which thefixture may be transported and/or guided. Other conveyor arrangementsare possible.

Further, it is noted that the conveyance arrangement may be configuredin such a manner that the fixture and thus also the base layer may bemovable in relation to e.g. a conveyor, track or the like. Such amovement may be controllable by e.g. a control system and perform in anautomated manner, e.g. in order to place the fixture in a suitableposition, orientation, inclination, etc. for the actual processing stepto be performed, e.g. for example when allowing a heat press to fixatethe footwear parts by activating the adhesive and thus e.g. pressingfrom above as well as below. Another example may be tilting the fixturewhen allowing an automated stitching apparatus to grip on upper andlower side of the base layer to perform the stitching, etc. Thus, theconveyance arrangement may be configured to have several degrees orfreedom, e.g. being able to rotate around vertical as well as horizontalaxes, tilt sideways and/or lengthways, etc.

In an embodiment of the invention, an identifier may be provided foridentifying at least one of the base layer, the fixture and at least oneof the at least two footwear parts.

Hereby, the identity of the actual piece of footwear being manufacturedmay be known, e.g. whether it is the fixture, the base layer or at leastone of the footwear parts that are proceeding along the manufacturingline that is identified. Thus, when proceeding along the manufacturingline and through the processing steps, the control system may read theidentity and perform the correct next step to be performed. Thus, it mayfor example be possible that the control system, when identifying theactual fixture, the actual base layer and/or an actual footwear part,may know that it is left hand shoe being made in size 39 with a specificcolour and that the next step is addition of a facing. The controlsystem may thus retrieve such a shoe part and place it in the correctposition, where after the fixture may be conveyed further on forfixation of the facing and subsequent automated stitching of the facingto the assembly. Hence, it will be understood that due to theidentifier, the actual footwear being made may be understood aseffectively controlling the manufacturing and processing steps, e.g.being the actual controller itself, in that the specific steps beingperformed will depend on the actual identity of the footwear beingmanufactured.

According to a particular embodiment, the identifier may be an RFIDdevice.

In an embodiment of the invention, the automated stitching device may beconfigured for stitching at least part of one of said at least twofootwear parts to the base layer.

Hereby, the automated stitching may be effected in a straightforwardmanner, e.g. by stitching through e.g. the at least two footwear partsas well as the underlying base layer. Further, it is achieved that partsof the base layer that in this manner is being stitched to the footwearparts that at least partly forms a footwear upper, may serve as a partof the completed piece of footwear.

In an embodiment of the invention, the system may be configured forremoval of the base layer from the at least two footwear parts prior tocompletion of the footwear or trimming of the base layer prior tocompletion of the footwear.

Hereby, the at least two footwear parts, when having been connected byautomated stitching and possibly after having been connected withfurther footwear parts, may be removed from the base layer and/orfixture at a suitable point in time, for example when stitching in asingle plane, i.e. 2D stitching has been made and subsequent stitchingin 3D is the next processing step and/or where the connected footwearparts are planned to be mounted on e.g. a last for the furtherprocessing steps. At these points in time, the base layer may possiblybe removed totally or only parts of the base layer that may not beneeded for the further processing and possible use in the completedfootwear may be removed, e.g. in connection with a trimming of thesurplus parts of the base layer and in connection with the removal of apossible fixture.

In an embodiment of the invention, the base layer may be the lining ofthe footwear.

Hereby, the base layer may fulfil the function both as a base layer andas lining of the footwear. This will effectuate the process of shoemaking as the step of adding a lining may not be necessary. Lining isdefined as the material inside of the shoe that may come into contactwith the entire foot; sides, top and heels. The lining may be anysuitable material such as e.g. leather or fabric such as cotton andviscose and/or synthetic material like e.g. polyester, acrylic andelastane. Other material for cold weather shoes may also be used such ase.g. wool or lambskin.

According to an embodiment of the invention, there may be a furtherlayer of lining e.g. as a middle layer between the base layer and thelayer of leather. An advantage of a middle layer could be improvedinsulation, rigidity, durability or other advantages suitable forfootwear.

In an embodiment of the invention, the system may further comprise aquality inspection system for inspection of said at least two footwearparts, e.g. when said at least two footwear parts have been positionedon the base layer, when said at least two footwear parts have beenfixated and/or when said at least two footwear parts have been connectedby an automated stitching.

Hereby, it may be controlled that the respective manufacturing stepshave been performed as intended, before proceeding to the next steps,and in case it turns out that non-acceptable tolerances are detected,corrective actions may be taken and/or the relevant inspected item maybe removed from the processing for correction and/or re-use. Theinspection may be made by means of vision means, camera means, radiationmeans, etc.

THE FIGURES

The invention will be explained in further detail below with referenceto the figures of which

FIG. 1 illustrates an exemplary footwear manufactured according to anembodiment of the invention,

FIG. 2 a illustrates a top view of an exemplary vamp with a toe cap andfacing according to an embodiment of the invention,

FIG. 2 b illustrates a top view of an exemplary vamp with a toe cap,facing and quarter according to another embodiment of the invention

FIGS. 3 a-c illustrate in perspective views an exemplary base layer,whereon footwear parts such as vamp and toe cap are positioned accordingto various embodiments of the invention,

FIG. 3 d illustrates the connected footwear upper parts as shown in FIG.3 b being folded into a 3D upper,

FIGS. 4 a-4 d illustrate in perspective views an example of initial orpreparatory steps of an automatic stitching method according to anembodiment of the invention,

FIG. 5 a illustrates an outlay seen from above of a module-basedmanufacturing line according to an embodiment of the invention,

FIG. 5 b illustrates a further outlay seen from above of a module-basedmanufacturing line according to an embodiment of the invention,

FIG. 6 is a schematic enlarged view of an example of a workstation forgripping a footwear part and placing it at a specific location at/on abase layer, seen from above,

FIG. 7 is a schematic enlarged view of an example of a workstation forautomated stitching of an assembly of footwear parts at/on a base layer,seen from above,

FIG. 8 illustrates an outlay seen from above of a module-basedmanufacturing line in continuation according to an embodiment of theinvention,

FIG. 9 illustrates a further example of an outlay seen from above of amodule-based manufacturing line according to an embodiment of theinvention, and

FIG. 10 illustrates a still further example of an outlay seen from aboveof a module-based manufacturing line according to an embodiment of theinvention, where further operation processes for manufacturing a pieceof footwear are illustrated.

DETAILED DESCRIPTION

FIG. 1 illustrates an exemplary footwear which may be made within thescope of the invention. The exemplified footwear is a shoe 10 comprisingan upper 11 wherein the upper 11 comprises footwear defining parts. Thefootwear defining parts are exemplified with a vamp 60 located as thesection of the upper that covers the front of the foot as far back asthe join of the quarter; a tongue 13 defined as a strip of materiallocated under the laces of a shoe. The tongue may sit on the top centerpart of the shoe on top of the bridge of the foot and may be attached tothe vamp 60; quarter 14 located on the rear and sides of the upper thatcovers the heel that are behind the vamp. The heel section of thequarter 14 may be strengthened with a stiffener, which helps support therear of the foot. Further, a toe cap 62 wherein toe caps can takevarious forms, but types may be complete replacements for the frontupper of the shoe; stitched over toecaps that add an extra layer to theupper; solid toe caps for protection, such as steel toe caps. Stitchover toe caps may be decorative in nature. Also, an outer counter 17located at the heel of the shoe as a stiff piece of material positionedbetween the lining and upper that helps maintain the shape of the shoe,eyelets 18 as the holes for shoelaces and facing 19 being the part ofthe shoe where the shoelace eyelets are located.

The illustrated shoe 10 may preferably comprise a lining 30 on the innerside of the quarter.

The illustrated shoe parts may preferably be attached to a sole 16 e.g.by adhesion, gluing, stitching, injection molding or any relevantmethods of attaching a sole. The sole may comprise several parts andlayers e.g. inner sole 20, mid-sole (not shown) and outer sole 16.

The shoe may of course comprise other not-shown features and parts andthe shapes and configuration of the parts may be different. Most shoesmay comprise more than 15 or 20 shoe defining parts.

FIG. 2 a illustrates a top view of parts of an upper e.g. of the shoe ofFIG. 1 , comprising a vamp 60, a toe cap 62 and facing 19 made withinthe scope of the invention. The vamp 60 and toe cap 62 are assembled byfitting the toe cap 62 on top of the vamp 60 as illustrated and thenattached together. The vamp and facing are in the same way assembled byfitting the facing 19 on top of the vamp 60 as illustrated and thenattached to each other.

The attachment of the leather pieces may be mediated by adhesion e.g.glue or any suitable adhesions but may also be a more lose attachment orthey may only be loosely assembled to each other.

The leather pieces may then be sewed together as illustrated with astitching line 22 by the method according to the invention. Stitchingmethods applied may be any methods relevant for stitching shoes.

FIG. 2 b illustrates in a similar manner a top view of parts of an uppere.g. of the shoe of FIG. 1 , where the parts comprise a vamp 60, a toecap 62, a facing 19 and a quarter 14 made within the scope of theinvention. The vamp 60 and toe cap 62 are assembled by fitting the toecap 62 on top of the vamp 60 as illustrated and then attached together.The vamp and facing are in the same way assembled by fitting the facing19 on top of the vamp 60 as illustrated and then attached to each other.

The quarter 14 and the vamp 60 are in the same way assembled by fittingthe quarter 14 on top of the vamp 60 at one side of the vamp asillustrated and then attached to each other.

The attachment of the leather pieces may be mediated by adhesion e.g.glue or any suitable adhesions but may also be a more lose attachment orthey may only be loosely assembled to each other.

The leather pieces may then be sewed together as it is illustrated witha stitching line 22 by an embodiment of the method according to theinvention. Stitching methods applied may be any methods relevant forstitching shoes.

As regards the embodiment shown in FIG. 2 b , it is noted thatsubsequent to e.g. stitching of footwear pieces, the part of the quarter14 pointing downwards in FIG. 2 b may be assembled with the other sideof the vamp 60, requiring that the parts are formed 3-dimensionally toessentially take the form of a shoe upper and stitched together asindicated with the stitching line 22 on the lower part of the quarter14.

It will be understood that other shoe parts in addition to the partsillustrated in FIGS. 2 a and 2 b may be introduced in similar mannersand assembled with the illustrated parts to eventually form an upper ofa shoe.

FIGS. 3 a-3 c illustrate in perspective views an exemplary base layer30, whereon footwear parts such as a vamp 60 and a toe cap 62 arepositioned in accordance with various embodiments of the invention. FIG.3 a illustrates a lining 30 being used as a base layer and with shoeparts exemplified by a vamp 60 and a toe cap 62 positioned on the baselayer 30. For reasons of clarity, only a few footwear parts areillustrated in FIGS. 3 a-3 c , but it will be noted that furtherfootwear parts may be positioned on the base layer, e.g. correspondingto the footwear parts as illustrated in FIGS. 2 a and 2 b and/or FIG. 1, which footwear parts may be processed in essence as described in thefollowing concerning the various embodiments of the method according tothe present invention. However, it is further noted that any relevantshoe parts or even accessories in the shoe manufacturing may be relevantin connection with the invention. After being positioned on the baselayer 30, e.g. by means of for example a pick and place robot, the vamp60 and the toe cap 62 are being fixated on the base layer, for exampleby activating an adhesive on the base layer. The non-activated adhesivemay be activated by using pressure, friction, ultrasonic radiation,infrared radiation, heat, possibly in any combination. When the footwearparts have been fixated, the base layer 30 comprising the fixatedfootwear parts can now—possibly after being inspected as regardsquality—be transported to e.g. an automated stitching station, where thefootwear parts are being connected to the base layer and/or each otherby an automatic stitching process as will be described in further detailbelow.

FIG. 3 b corresponds to FIG. 3 a , but here it is illustrated that aquarter 14 has been positioned at one side of the vamp 60, fixated onthe base layer 30, etc. in such a manner that by a subsequent stitchingprocess the footwear parts are being connected together and to the baselayer.

FIG. 3 c corresponds essentially to the scenario as shown in FIG. 3 b ,but in FIG. 3 c it is illustrated that the base layer material isexploited to a greater degree by placing footwear parts, e.g. a furthervamp 60, toe cap 62 and quarter 14, forming a further footwear upper,where these further parts form a mirrored version of the first mentionedfootwear parts such that the first may relate to a left footwear upperand the second may relate to a right footwear upper. Another advantagemay be that a pair of footwear uppers, e.g. relating to one and the samesize, type, etc. in this manner may be processed simultaneously and/orfollowing each other in the manufacturing process.

FIG. 3 d illustrates the footwear upper parts as shown in FIG. 3 b afterthey have been connected by stitching and where the superfluous parts ofthe base layer have been trimmed off, thus leaving essentially only thebase layer 30 that is on the underside of the parts 14, 60 and 62.Hereafter, a folding of the connected footwear parts into a 3D upper maybe performed as illustrated by the arrow A. Subsequently, the footwearupper may be connected and stitched as it has been explained above inconnection with FIG. 2 b . It is noted that the base layer material willthus serve as a lining in the manufactured footwear upper.

FIGS. 4 a-4 d illustrate an example of initial or preparatory steps ofan automatic stitching method according to an embodiment of theinvention, wherein a fixture 40 is utilized in the processing steps asit will be explained in detail further below. The fixture may beconfigured in a multitude of variations. However, in order to elucidatethe invention, the fixture 40 is here illustrated, seen in a perspectiveview partly from above and partly from the side, as being an essentiallyrectangular fixture frame 42 as shown in FIG. 4 a , which fixture frameserves to withhold a base layer. Further, it is noted that the fixture40 comprises or can be combined with conveyance arrangements 44(indicated in FIG. 4 a ), e.g. placed underneath the fixture frame 42and configured for facilitating a controllable transport, e.g. along aconveyor, along a track or in any other suitable manner.

As indicated in FIG. 4 b , the fixture 40, e.g. the fixture frame 42 isconfigured for holding a base layer 50. For example, the fixture frame42 may have a clamping function, e.g. by being openable and closable,and a base layer 50 may thus be gripped by the fixture frame 42 alongthe outer perimeter of the base layer. The base layer 50, which is anessentially non-stretchable material, is held by the fixture 40 in sucha manner that the base layer 50 extends in a plane defined by thefixture and essentially without deviating from the plane at locationswithin the inner of the fixture frame. As further indicated in FIG. 4 b, a reference 52 may be defined in the 2-dimensional plane defined bythe base layer 50, e.g. for example at a corner of the fixture frame 42,which reference may serve as reference point for the further processing,e.g. when positioning footwear parts, when stitching, etc. as it will beexemplified further below. The reference 52 may be defined in othermanners, e.g. by having a marking on the base layer 50, for examplevisible and/or detectable by e.g. vision equipment, detecting apparatus,etc.

In FIG. 4 c it is shown that the fixture 40 with a base layer 50 mountedhas been placed in a processing line and based on the reference 52 andin accordance with work instructions, e.g. control software, a footwearpart such as e.g. a vamp 60 is positioned on the base layer 50 in aposition and possibly with an orientation in accordance with the workinstructions, e.g. the control software. The footwear part may forexample be gripped and positioned on the base layer by a pick and placerobot or another type of robotic apparatus.

In the next step, it is illustrated in FIG. 4 d that a further footwearpart, e.g. a toe cap 62, has been positioned at least partly overlappingthe previously positioned footwear part. The toe cap 62 may bepositioned based on the reference 52 and in accordance with workinstructions, e.g. control software, for e.g. a pick and place robot orthe like. It is noted that the control software may receive input notonly regarding the reference 52 but may also receive input as regardsthe actual position and/or orientation of the previously placed footwearpart. It is noted that it is a possibility that the latter positionedpart, e.g. the toe cap 62, may be positioned based alone on the positionof the former positioned part, e.g. the vamp 60. A combination may bepreferable, though.

Furthermore, it is indicated in FIG. 4 d that an identifier 70 may bearranged on the fixture 40, e.g. on, at or in the fixture frame 42.Instead or in addition such an identifier 70′ may be arranged inconnection with the base layer 50. Further, it is noted that theidentifier, which in such case will be referred to as 70″, instead oradditionally may be arranged in connection with the footwear parts, e.g.on or in one or more of the footwear parts.

Hereby, the fixture, the base layer with the parts being positioned onit and/or the footwear part(s) may be e.g. tracked along a processingline and in case a control system has been provided with informationconcerning the involved identifiers, the relevant processing may beperformed in accordance with e.g. a predefined set of specifications asthe parts proceed along the processing line. Further, it is noted thatthe use of such identifiers may allow that e.g. a particular fixture,base layer and/or footwear parts may be removed from e.g. the processingline and later added again, at which stage the identifier may be read bya reader and an e.g. status of steps already performed may be providedto the control system as well as the actual characteristics of the workin progress.

As an example, it may be mentioned that the identifier devices may beRFID devices or any other suitable electronically readable devices.

Furthermore, it should be noted that the exemplary footwear parts shownin FIGS. 4 c and 4 d , e.g. a vamp 60 and a toe cap 62, are forillustrative purposes only and that other footwear parts may be used asexemplary footwear parts such as shown and explained in connection withFIGS. 2 a, 2 b and 3 a-3 c . Thus, it will also be understood that afixture 40 with a base layer 50 may be utilized when positioningfootwear parts for a single footwear upper, e.g. as it has beenillustrated in FIGS. 4 c and 4 d , but that advantageously a pair offootwear uppers may be processed on a single fixture with a base layersuch as it has been explained with reference to FIG. 3 c . Furtherconfigurations are possible, e.g. with a single fixture frame 42 and itsassociated base layer 50 carrying parts for more than two footwearuppers, etc. if the sizes permits. Even further, as mentioned above, itshould be noted that the base layer 50 may be utilized in a completedfootwear upper as a lining 30.

In FIG. 5 a a possible outlay of a module-based manufacturing line 100according to an embodiment of the invention is illustrated, seen fromabove. Here, a number of modules 101-109 are shown, which may beutilized in connection with a manufacturing line for footwear and wheree.g. footwear parts, materials, etc. necessary for the manufacture aswell as subparts of the e.g. footwear may be transported along themanufacturing line 100, e.g. generally from left to right in FIG. 5 a ,while manufacturing steps, handling, etc, are being performed along theline 100. As illustrated in FIG. 5 a , the transport, e.g. conveying maytake place along the hatched route and as illustrated with the arrows asit will be further elucidated in the following.

It should be noted that the respective modules are configured withinterfaces, e.g. clear mechanical, pneumatic, electronic and/orcommunication interfaces, thereby enabling a quick reconfiguration ofthe modules and the line 100 to accommodate manufacture of e.g. new orchanged products, to enable additional modules to be included, e.g. afurther workstation for automatic stitching, etc.

The module 101 is a module for a stacking device, where stacks of e.g.footwear parts, base layers, etc. S1, S2, S3 and Sn may be fed to theline. In particular, the module 101 may handle stacks of fixtures 40,each comprising a fixture frame 42 and a base layer 50 that may be alining material 30, which e.g. one by one are fed to the manufacturingline 100. From this module 101 for a stacking device the objects may beforwarded to different locations via a module 102 for 3-way transfer asillustrated by the arrows, e.g. moved across the module 103 to the nextmodule 104 or directed to the module 103, e.g. a work station, at theside. Also, the module 102 for 3-way transfer may serve to forwardobjects from the module 103, e.g. a work station, to the next module104. The module 103 at the side of the line may be a work station suchas a module for a pick and place device, which furthermore may comprisea visual detection system to enable the pick and place device to e.g.grip a footwear part and place it at a specific location at/on a baselayer. Furthermore, the pick and place device at the module 103 may e.g.grip one or more further footwear part(s) and place it (them) at afurther specific location at the base layer and/or at overlappingpositions on the first placed footwear part. Also, it should be notedthat the pick and place device may place the footwear part(s) with adesired orientation, e.g. in relation to the base layer and/or inrelation to a previously placed footwear part.

As it will be understood from the foregoing, the object beingtransported from the module 103 to the module 104 may be a base layer,upon which two or more footwear parts are positioned. At the module 104a heat press device or another type of device for activating a layer ofnon-activated adhesive on the base layer is arranged for activating theadhesive as previously discussed, thereby fixating the footwear parts onthe lase layer in the positions, in which they have been placed.

The base layer with the fixated footwear parts may next be forwarded toa module 105 having a process quality inspection system, e.g. having avision or camera component for checking e.g. the positions of thefootwear parts, the overlap, etc. In case there is any flaw, thespecific base layer with footwear parts may proceed e.g. directly to theend of the line, may be redirected without being used or may be removedin another manner, in all cases possibly for being corrected, used forother purposes or in other manners reused.

When the base layer with footwear parts passes the module 105 having theprocess quality inspection system, it reaches a second module 106 havinga 3-way transfer as illustrated by the arrows. Here, the base layer withfootwear parts may be directed to module 107, e.g. a workstation havingan automated stitching device in the form of e.g. a robotic stitchingsystem, by means of which the fixated footwear parts and possibly thebase layer are being connected to each other by stitching.

When having been stitched, the base layer with the fixated and nowconnected footwear parts is being transported to a module 108 for astacking device, where a stacking of the processed base layers with thefixated and now connected footwear parts is being performed before beingsubjected to further processing in order to provide a completed piece offootwear. Here, the further processing may include removal of the baselayer 50 with the connected footwear parts from the fixture frames 42,whereafter the fixture frames may be prepared for being returned to theinput of the manufacturing line 100.

Furthermore, a module 109 is illustrated, which is a module for afixture or jig preparation device, where for example base layers 50 maybe mounted in or on the individual fixtures 40 and in general made readyto enter a manufacturing line 100 as illustrated in FIG. 5 . The module109 may for example comprise a movable magazine, which can be moved tothe module 101 when the magazine has been filled with fixtures 40, whichhave been provided with new base layer material.

In FIG. 5 b a further example of a manufacturing line 100 isillustrated. This corresponds in essence to the manufacturing line thathas been shown in FIG. 5 a and has been explained in connection withFIG. 5 a . However, in FIG. 5 b the fixture preparation module 109 isplaced in front of the manufacturing line 100. Further, the fixturepreparation module 109 as well as the module 108 for a stacker device atthe end of the manufacturing line 100 may comprise an elevator each.Even further, an underlying conveyor 111, e.g. a conveyor belt, isarranged, leading from the module 108 to the fixture preparation module109. This underlying conveyor 111 may be arranged in lower parts of therespective modules, e.g. arranged under a conveyor 110 that transportsfixtures in the manufacturing direction. Thus, fixture frames thatarrive at the module 108 may be lowered down by the elevator andtransported to the fixture preparation module 109 by the underlyingconveyor 111. Here, they are lifted upwards and may be prepared byremoving any base material left and by mounting a new piece of baselayer material in the fixture frame. This may be done by an operator118, who also pushes the now prepared fixture frame to the module 101for a stacking device, ready to be used in the manufacture. The module101 for a stacking device may hold a plurality, e.g. 5 or more, offixture frames and may thus serve as a buffer.

The fixture handling and transport arrangement shown in FIG. 5 b may beused in connection with other manufacturing line configurations as well,e.g. the examples shown in FIGS. 8, 9 and 10 .

In FIG. 6 an example of a schematically shown workstation 103 forgripping a footwear part and placing it at a specific location at/on abase layer is shown in an enlarged view from above. Here, it is shownthat a fixture 40 comprising a base layer 50 have been transported tothe workstation 103 by e.g. a conveyor 110. The workstation comprises apick and place robot 114, which has a robot arm 115, for example anarticulated and extendable arm that may be rotated around a base partand which has a gripper such as a vacuum gripper 116. It is noted thatvarious types of robots may be utilized for picking and placing thefootwear parts and it should be mentioned that for example a SCARA robotmay be utilized. It is furthermore noted that in case a robotic vacuumgripper is used, this may be equipped with a plurality of relativelysmall suctions cups or the like, e.g. arranged in an array correspondingto e.g. the size of footwear parts to be gripped. The individual suctioncups or the like may be individually supplied with vacuum. Additionally,it is noted that a further axis of the vacuum gripper robot may beimplemented by having the active suctions cups or the like, e.g. thesuction cups actually gripping a footwear part, be controlled to beextended or in another configuration by having the inactive suction cupsbe controlled to be retracted, when gripping, positioning and/or movingetc. a footwear part. Hereby, a number of advantages may be achieved,e.g. that the inactive suctions cups or the like that are actually notinvolved in gripping a footwear part, will not be near or will at leastbe positioned a distance from the footwear part, thus making it easierto maneuver the vacuum gripper and/or the gripped footwear part, e.g.because the inactive suctions cups or the like are less likely tocollide with other objects, for example a fixture for the base layer,conveyor parts or other parts involved in the processing. Hence, therobotic vacuum gripper may, when implemented in such a manner with afurther axis, be used with greater delicacy, with greater precision andin general with greater degrees of freedom as regards e.g. the abilityto turn or in general angularly maneuver a footwear part, position afootwear part near a frame or fixture for the base layer, utilize theavailable base layer area to a greater extent, etc.

The workstation 103 may furthermore comprise a visual detection systemto enable the pick and place device to operate, where the visualdetection system may comprise a detector device 112 that may beconnected to various detectors, cameras, vision devices in order toprovide the desired to the e.g. robot 114.

The robot 114 is controlled by software to pick individual footwearparts, e.g. leather parts and place these on the base layer 50 atspecified positions, in a certain order, etc. as it has been explainedabove. These footwear parts may be picked from e.g. leather partsupplies 120. When the fixture 40 with the base layer 50 has receivedfor example two assemblies 64 of footwear parts, it may be transportedfurther on in the processing line, e.g. to the module 104 for activatingadhesive or to another module. Also, it may be parked for a longer orshorter time until processing capacity is ready, for example at theworkstation 103 that may also serve as a buffer.

In FIG. 7 an example of a schematically shown workstation 107 forautomated stitching is shown in an enlarged view from above. Here, it isshown that a fixture 40 comprising a base layer 50 and whereon forexample two assemblies 64 of footwear parts are fixated has beentransported to the workstation 107 by e.g. a conveyor 110.

The workstation 107 comprises a schematically illustrated automatedstitching apparatus 130, which is arranged in connection with a gantrydevice 132, possibly a gantry robot, in such a manner that relativemovement in the transverse as well as the conveyor direction (thelongitudinal direction) is facilitated. Thus, the footwear parts of thee.g. two assemblies 64 may in this manner be stitched to the base layer50 and to each other.

The workstation 107 may furthermore comprise a visual detection systemto enable the automated stitching apparatus 130 to operate, where thevisual detection system may comprise a detector device 112 that may beconnected to various detectors, cameras, vision devices in order toprovide the desired control signals to the e.g. gantry device 132 andthe automated stitching apparatus 132. These are controlled by softwareto e.g. perform a stitching along predefined routes, along certain edgesof the footwear parts or in any other manner to provide a predefinedstitching of the footwear parts. When the stitching of the twoassemblies 64 of footwear parts have been performed, the fixture 40 withthe base layer 50 and the two assemblies 64 of footwear parts may betransported further on in the processing line, e.g. to the module 108for further processing. However, it may be parked for a longer orshorter time until processing capacity is ready, for example at theworkstation 107 that may also serve as a buffer.

In FIG. 8 a possible outlay of a continuation of a module basedmanufacturing line 100 according to an embodiment of the invention isillustrated, seen from above. Here, the modules are illustrated as acontinuation of modules e.g. from a series of modules 100 that may be aseries of modules as illustrated in FIG. 5 a . It may also be acontinuation of the illustrated modules to other manufacturing processesrelevant for footwear making.

In FIG. 9 a further example of a manufacturing line 100 is illustrated.This corresponds in essence to the manufacturing line that has beenshown in FIG. 5 a and has been explained in connection with FIG. 5 , butin FIG. 9 it is exemplified that quality inspection may be performed atdifferent steps in the manufacturing line 100. In FIG. 5 a it was shownthat a module 105 for process quality inspection was placed followingthe module 104 for activation of adhesive. As shown in FIG. 9 , themodule 105 for process quality inspection may instead be placedfollowing immediately after the automated stitching has been performed,e.g. after the module 107 for automated stitching and the module 106 for3-way transfer. It will be apparent that a process quality inspectionmay be performed at both of these exemplified positions, at only one ofthese and/or at any other suitable position.

Furthermore, it should be noted that other configurations of the variousmodules 101-109 are possible in addition to the configurationsexemplified in the figures. For example, it is noted that whereas is itshown that the modules 103 and 107 relating to the robotic positioningof shoe parts on fixture frames holding base layer and the automatedstitching, respectively, are exemplified as stations, where the objectsare being removed from a main process line and are being processed ine.g. a loop configuration, it is a possibility that these operations maybe performed as inline processes, e.g. being performed in the mainprocess line without being looped out.

In FIG. 10 a further example of a configuration of a manufacturing line100 is illustrated. This corresponds in essence to the manufacturingline that has been shown in FIG. 5 and has been explained in connectionwith FIG. 5 , but here it is further shown that the output from themodule 108, e.g. base layers with stitched footwear parts that have beenstitched in a 2 dimensional plane and where e.g. the surplus base layerhas been trimmed so that the remaining base material may serve aslining, is being forwarded to a further 3D processing 140. This 3Dprocessing 140 may e.g. include closing the footwear uppers by stitchingthem together as it has been explained above, e.g. in connection withFIG. 3 d and may further comprise attaching Strobel material to the 3Dupper in advance of e.g. injection of sole material. Further processesmay be performed here at 140, as it will be apparent to a person skilledwithin the field of footwear manufacture. Next, the completed footwearupper is forwarded to a sole attachment process, such as for example adirect injection production (DIP) 150 and related operations, resultingin a completed piece of footwear 10.

In principle, the leather can derive from any source, includinganimal-sources such as bovine hide, cow hide, horse hide, goat skin,sheep skin, kangaroo hide, reptiles, fish and the like. The leather mayalso derive from a non-animal sources such as e.g. natural materialsderived from e.g. plants, unicellular or multicellular organisms. Evenso, preferably the leather is a mammal or marsupial leather (i.e.derives from a hide from a mammal such as horse or bovine e.g. cow, or amarsupial such as a kangaroo. Mammal leathers are most often used.However, it should be noted that one or more of the footwear parts beingused for the manufacture of e.g. footwear uppers in connection with thepresent invention may comprise other materials, e.g. synthetic materialssuch as polyester, polyamide and/or polyurethanes.

LIST OF REFERENCE NUMBERS

-   10 Shoe-   11 Upper-   13 Tongue-   14 Quarter-   16 Outer sole-   17 Outer counter-   18 Eyelet-   19 Facing-   20 Inner sole-   22 Stiches-   30 Lining-   40 Fixture-   42 Fixture frame-   44 Conveyance arrangements-   50 Base layer-   52 Reference-   60 Vamp-   62 Toe cap-   64 Assembly of footwear parts-   70, 70′, 70″ Identifier-   100 Manufacturing line-   101 Module for a stacking device-   102 Module for 3-way transfer-   103 Workstation-   104 Module for activating adhesive-   105 Module for process quality inspection-   106 Further module for 3-way transfer-   107 Workstation for automated stitching-   108 Further module for a stacking device-   109 Fixture preparation module-   110 Conveyor-   111 Underlying conveyor-   112 Detector device-   114 Pick and place robot-   115 Robot arm-   116 Vacuum gripper-   118 Operator-   120 Leather part supply-   130 Automated stitching apparatus-   132 Gantry device-   140 3-dimensional (3D) processing-   150 Direct injection production (DIP)-   A Folding of 3D upper-   S1-Sn Stacks of footwear parts, base layers, etc.

1. A method of manufacturing footwear, said footwear comprising at leasttwo footwear parts, which are shoe parts, and which footwear parts areat least partly connected together by stitching for forming at leastpart of an upper part of said footwear, said method comprising:providing a base layer, providing said at least two footwear parts andpositioning said at least two footwear parts on said base layer,fixating said at least two footwear parts on said base layer inrespective relative positions corresponding to predefined connectedpositions, connecting said at least two footwear parts with each otherby an automated stitching, and processing the at least two footwearparts in connected form to provide said footwear.
 2. The methodaccording to claim 1, wherein at least one of said at least two footwearparts is a leather footwear part.
 3. The method according to claim 1,further comprising: providing a fixture for said base layer; andarranging the base layer to be held by said fixture.
 4. The methodaccording to claim 1, wherein a reference is provided for positioningsaid at least two footwear parts on said base layer.
 5. (canceled) 6.The method according to claim 1, wherein said fixating said at least twofootwear parts on said base layer in respective positions comprisesadhering the at least two shoe parts on said base layer with anadhesive.
 7. The method according to claim 6, wherein said adhesive isprovided as a non-activated adhesive on said base layer, which isactivated when fixating the at least two footwear parts on the baselayer. 8.-9. (canceled)
 10. The method according to claim 1, wherein thepositioning of said at least two footwear parts on said base layer isperformed by a robotic pick and place apparatus by sequentially pickingeach shoe part and placing each shoe part on the base layer at apredefined position.
 11. (canceled)
 12. The method according to claim 1,wherein the positioning of said at least two footwear parts on said baselayer is performed using input from a visual detection system includingusing a camera or a vision system.
 13. (canceled)
 14. The methodaccording to claim 1, wherein said at least two footwear partssubsequent to being positioned on said base layer, are transportable bymoving said base layer.
 15. (canceled)
 16. The method according to claim1, wherein an identifier is provided for identifying at least one of thebase layer, the fixture, and at least one of the at least two footwearparts.
 17. The method according to claim 1, wherein the automatedstitching includes stitching at least part of one of said at least twofootwear parts to the base layer.
 18. (canceled)
 19. The methodaccording to claim 1, wherein the base layer is a lining of thefootwear. 20.-25. (canceled)
 26. A system for manufacturing footwear,said footwear comprising at least two footwear parts, which are shoeparts, and which footwear parts are at least partly connected togetherby stitching for forming at least part of an upper part of saidfootwear, said system comprising: a base layer holding device configuredfor holding a base layer, a positioning device for positioning at leasttwo footwear parts on said base layer, an adhering activating deviceconfigured for fixating said at least two footwear parts on said baselayer in respective relative positions, an automated stitching deviceconfigured for connecting said at least two footwear parts with eachother, and at least a further processing device for facilitating furtherprocessing of the at least two footwear parts in connected form toprovide said footwear.
 27. (canceled)
 28. The system according to claim26, wherein said base layer holding device configured for holding saidbase layer is a fixture.
 29. The system according to claim 28, whereinsaid fixture comprises conveyance arrangements configured for transportof said fixture.
 30. The system according to claim 26, wherein saidpositioning device comprises a robotic apparatus including a roboticpick and place apparatus.
 31. The system according to claim 26, whereinsaid positioning device comprises a visual detection system includingone or more of a camera or a vision system.
 32. The system according toclaim 26, wherein said adhering activating device configured forfixating said at least two footwear parts on said base layer inrespective relative positions comprises an arrangement for activatingnon-activated adhesive using at least one of friction, pressure,ultrasonic radiation, infrared radiation, or heat transfer. 33.-40.(canceled)
 41. The system according to claim 30, wherein said roboticpick and place apparatus comprises a vacuum gripper. 42.-46. (canceled)47. The system according to claim 26, wherein an identifier is providedfor identifying at least one of the base layer, a fixture, and at leastone of the at least two footwear parts. 48.-51. (canceled)